Battery Pack Frame Structure for BMU Impact Resistance
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Solution Overview
Problem
Conventional battery packs are prone to bending under external forces, which can damage the battery management unit (BMU) and compromise assembly quality.
Innovation Solution
A battery pack design featuring a frame unit with a support frame and BMU cover, including ribs and receiving portions, to enhance impact resistance and protect the BMU from bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a rectangular structure with battery cells disposed side by side is used, then the device size is reduced, but the battery pack becomes easily bent by external force in the longitudinal direction
Solution Approach 1:
The patent introduces a support frame with ribs extending in the width direction (transverse to the longitudinal bending direction) to create a three-dimensional reinforcement structure. This adds dimensional complexity to resist bending while maintaining the compact rectangular footprint of the battery pack.
Solution Approach 2:
The frame unit combines the outer frame, support frame, and BMU cover into a composite structural assembly that provides enhanced rigidity and impact resistance compared to a simple rectangular housing, while still accommodating the battery cells in a compact arrangement.
2Strength
If the frame structure is reinforced to prevent bending, then impact resistance is improved, but the complexity of the frame structure increases
Solution Approach 1:
The frame structure is segmented into distinct functional components: an outer frame for boundary definition, a support frame with ribs for structural reinforcement, and a BMU cover for component protection. This segmentation allows each part to be optimized for its specific function while assembling into a cohesive whole.
Solution Approach 2:
The support frame incorporates ribs with varying thicknesses (first seating portion and second seating portion with different thicknesses) at specific locations to provide localized reinforcement where needed, particularly around the BMU area, rather than uniformly thickening the entire frame structure.
3Reliability
If the BMU area is reinforced to prevent bending, then BMU protection is improved, but the welding quality and assembly convenience may be affected
Solution Approach 1:
The support frame is designed with pre-formed seating portions and recesses that precisely position the BMU and battery cell terminals before assembly. This preliminary structuring ensures proper alignment and facilitates convenient welding operations without requiring complex adjustment procedures during assembly.
Data Source
AI summary
A battery pack can include a frame unit including an outer frame configured to define a receiving space and a support frame located inside an edge of one side of the outer frame, a battery cell received in the receiving space, a battery management unit (BMU) having one surface facing an upper surface of the support frame, the BMU being electrically connected to the battery cell, and a BMU cover including a cover plate located at another surface of the BMU, wherein the frame unit includes a first rib and a second rib.